British Journal of Applied Science & Technology

6(6): 621-634, 2015, Article no.BJAST.2015.117

ISSN: 2231-0843

SCIENCEDOMAIN international
www.sciencedomain.org

The Influence of Multiple Welding Repairs of

Pipelines in Residual Stress Assessment Related to
Stress Corrosion Cracking
A. Contreras1*, S. L. Hernndez1, R. Galvan2 and O. Vega3
1
Mexican Petroleum Institute, Eje Central Lzaro Crdenas Norte 152, Col. San Bartolo Atepehuacn,
CP 07730, Mexico.
2
University of Veracruz, Institute of Engineering, Unit Anti-corrosion, Pope John Paul II Ave. S / N,
Ciudad Universitaria, Fracc, Costa Verde, Veracruz, CP 94294, Mexico.
3
Research Center for Advanced Materials S.C., Unit Monterrey, Northern Alliance 202, Park Research
and Technological Innovation. Apodaca, Nuevo Len, CP 66600, Mexico.

Authors contributions

This work was carried out in collaboration between all authors. Author AC designed the study,
supervise all the work, perform analysis of experimental results and reviewed the final manuscript.
Author OV performed the experimental studies, make the analysis of results and wrote the first draft of
the manuscript. Authors SLH and RG help to carried out the SSRT, analysis results and literature
searches. All authors read and approved the final manuscript.

Article Information

DOI: 10.9734/BJAST/2015/14931
Editor(s):
(1) Grzegorz Golanski, Institute of Materials Engineering, Czestochowa University of Technology, Poland.
(2) Singiresu S. Rao, Department of Mechanical and Aerospace Engineering, University of Miami, USA.
Reviewers:
(1) Anonymous, Brazil.
(2) Hao Wang, State Key Laboratory of Rolling and Automation, Northeastern University
P. R. China.
Complete Peer review History: http://www.sciencedomain.org/review-history.php?iid=769&id=5&aid=7689

th
Received 29 October 2014
Original Research Article Accepted 10th December 2014
th
Published 9 January 2015

ABSTRACT

The effect of residual stress of multiple welding repairs in seamless API 5L X52 on the stress
corrosion cracking (SCC) susceptibility was evaluated. Four repairs of the girth weld were
evaluated through X-ray diffraction (XRD) on the internal face of the pipe to measure residual
stresses in longitudinal and circumferential direction. Residual stresses in the circumferential and
longitudinal direction reach values of about 77% and 58% of the UTS (460 MPa) respectively,
approaching to the YS of the steel (360 MPa). It was observed that its magnitude increases as
move away from weld center line. SCC susceptibility of X52 steel welded joints with the residual
_____________________________________________________________________________________________________

*Corresponding author: E-mail: acontrer@imp.mx;

 Contreras et al.; BJAST, 6(6): 621-634, 2015; Article no.BJAST.2015.117

stresses generated was evaluated through slow strain rate tests (SSRT) in a soil solution at low
and high pH. Relation between mechanical properties and residual stresses on the SCC
susceptibility was analyzed. SCC index obtained from the mechanical properties of SSRT indicate
good SCC resistance of X52 steel exposed to soil solution at low and high pH. From these results,
it is suggested that the region with high residual stresses before to generate cracks in the steel
surface due to the combination of soil solution and the strain applied, should favor pitting formation
and not cracking. Initiation of micro-cracks from these pits will depend on the geometrical form of
the pit and the stresses state can be established at given pitting. It is suggested that initiation of
micro-cracks from these pits may depend on the dissolution rate and morphology of the pitting and
stresses on the bottom of the pitting. This favorable condition could appear increasing the soil
exposition time of the steel and reducing the strain rate applied on the SSRT.

Keywords: Steel; welding; x-ray diffraction; residual stresses; stress corrosion cracking (SCC).

1. INTRODUCTION of high temperatures close to the weld bead.

Residual stresses can be defined as those
stresses that remain within a material after been
manufactured, processed, heat treated or welded
in the absence of external forces or thermal
gradients [1]. The magnitude of residual stresses
must be known when the integrity of a structure
is assessed. Mostly, surface tensile residual
stresses are undesirable. Welding, machining
and grinding are examples of operations that
generate surface tensile stresses. In almost
every step of material processing residual
stresses can be arise due to mechanical effects
(generate by plastic deformation as a result of
processes during production), thermal effects
(generated as a result of heating or cooling
processes), and chemical effects (generate by
reaction such as precipitation or chemical
surface treatment [2].
Residual stresses are categorized based on the
length scale over which they equilibrate [3,4].
Type I which refers to macro residual stresses
that develop in the body of a component on a
scale larger than the grain size of the material.
Type II are micro residual stresses found at the
grain-size level, which vary on the scale of an
individual grain. Such stresses may be expected
to exist in single phase materials because of
anisotropy behavior of each grain. They may also
develop in multi-phase materials because of the
different properties of the different phases. Type
III is generated at the atomic level. They are
micro residuals stresses that exist within a grain,
essentially as a result of the presence of
dislocations and other crystalline defects. Types
II and III are often grouped together as micro
stresses.
Welding process generally involves the
deposition of molten filler metal and the presence
Consequently, the surrounding parent material
suffer microstructural changes which is reflected
in the mechanical properties such as elastic
modulus, elongation, yielding strength, hardness
and ultimate tensile strength. When a defect is
detected in a weld by means of some
nondestructive test, the weld must be remove
and repaired [5]. Generally, the girth weld metal
is removed by grinding and the groove is
prepared again in order to re-weld under a
qualified welding procedure.
The welding process generates large residual
stress gradients around the weld bead, which
can be particularly detrimental to the structural
integrity of a pipeline. In order to be able to
predict the service life of a pipeline, it is important
to have a proper knowledge of the residual stress
distribution in the vicinity of the weld region.
Among the nondestructive evaluation (NDE)
techniques available for this purpose, X-ray
diffraction (XRD) offers the more interesting
perspectives, since it can deliver relevant
information about the strain network state and
microstructural changes. The XRD technique is
used to evaluate microdeformations,
characterized by the XRD peak. X-ray diffraction
can directly measure this inter-planar atomic
spacing; from this quantity, the total stress on the
metal can then be obtained [6]. It is also an
efficient tool in studying the evolution of residual
stress in a mechanical structure under static or
dynamic loading. The disadvantage for this
technique is the low deep of analysis (superficial
assessment). For deeper analysis the neutron
diffraction is used [7,8]. The main advantage of
the neutron diffraction method is its high
penetration capacity for inspection materials up
to several millimeters in depth. The disadvantage
of such a technique is the high cost. There is
another method like finite element method (FEM)

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 Contreras et al.; BJAST, 6(6): 621-634, 2015; Article no.BJAST.2015.117
used to simulated the numerical description of
residual stresses in welded structural
components (including pipelines) which uses the
thermalmechanical analysis approach [9,10].
In many cases in pipelines where unexpected
failure has occurred, this has been due to the
presence of residual stresses which have been
combined with the service stresses to induce
cracks that growth with the time until produce a
suddenly failure (commonly rupture) [11]. In
multiphase materials, residual stresses can arise
from differences in thermal expansion, yield
stress, or stiffness [5,12].
One of the mainly adverse effect of residuals
stresses are in the susceptibility of stress
corrosion cracking (SCC) of buried pipelines. The
SCC failures are due to the fracture of metallic
materials when they are subjected to stress (that
can be residual, operational, etc) in a corrosive
solution that can be acidic, neutral or basic.
These failures are more likely in acidic media,
and there are many studies on the effect of
concentration, temperature, the stress in the
metal, roughness and the microstructure of the
material [13-17].
The stress exerted on the pressured
transmission pipeline is complex in nature. The
stresses generally speaking are a combination of
stresses related to the internal operating
pressure, residual stress from pipe fabrication
and construction and external forces.
The tensile stresses are a necessary parameter
for initiate SCC, however little research has
focused on defining the role of stresses in crack
initiation and growth [18,19]. For example, NACE
SP 204 and ASME B31.8S [20,21] establish a
criterion of 60% of the specified minimum yield
strength (SMYS) in order to nucleate cracks on
the surface of a pipeline. However, it has been
found failures in pipelines with operation
pressure less than 60% of the SMYS [22,23].
This suggests that SCC in pipelines is a
multifactorial phenomenon and of course time
dependant.
Weldments in pipelines are critical to maintain
structural integrity, but unfortunately these
weldments produce residual stresses, therefore
assessment of residual stresses play a key role
in operating pipelines. In the case of pipelines
operating under cyclic load or at high
temperature, the presence of tensile residual
stresses can increase the likelihood of time
623
dependent failure by acting as a driving force for
the initiation and growth of cracks. Therefore, is
very important to evaluate the residual stresses
after make several repairs in the pipelines
through submerged arc welding (SAW) or
shielded metal arc welding (SMAW) joining
technique.
This research work analyzed the effect of
residual stresses produced by multiple welding
repairs on the SCC behavior of X52 pipeline
steel exposed to a soil solution with low and high
pH using SSRT.
2. EXPERIMENTAL DETAILS
2.1 Steel Used
The material used in this work was a seamless
API X52 pipeline steel. The dimensions of the
pipeline were 8 inches in diameter and 0.437
inches in nominal wall thickness. The chemical
composition is shown in Table 1.
Optical and scanning electron microscopy (SEM)
observations of the microstructure for the
different welding repairs were carried out.
Additionally, SEM analysis of the failure zone
was performed.
2.2 Welding Procedure
The girth welds were obtained from the quality
control department of the company CMM-
PROTEXA, carried out by qualified welders
under a qualified welding procedure according to
API 1104 standard [24], using the SMAW
process with V-bevel at 30 as is shown in Fig. 1.
To simulate multiple welding repairs, the repaired
weld was removed and welded again, to obtain a
second, third and fourth welding repair. The
specimens obtained according to the number of
welding repairs were identified as 0R (as-
welded), 1R, 2R, 3R and 4R respectively. The
repair was made on the whole circumference of
the pipe specimen.
The qualification of welding procedures was
according to API 1104 and ASME Section IX
which are applicable standards to the welding of
pipelines. The specifications and procedures
used in welding establish that in order to make
welding repairs in areas previously repaired
indicate that the welding repair should be carried
out with a qualified procedure.
 Contreras et al.; BJAST, 6(6): 621-634, 2015; Article no.BJAST.2015.117
Table 1. Chemical composition of API X52 pipeline steel (wt.%)
C Mn Si P S Cu Cr
0.09 0.89 0.30 0.006 0.0015 0.12 0.07
Fig. 1. a) Schematic of the V-bevel at 30, b) notch after been removed the metal to repair and
c) piece of pipe after been welded
2.3 Residual Stress Assessment
Most of techniques used to evaluated residual
stresses, measure strains instead of stresses,
and the residual stresses are then deduced using
the appropriate material parameters such as
Young modulus and Poisson ratio [1,3,4,9].
During this assessment is very common obtain
only a single stress value and this value is
constant assumed within the measurement
volume, both in the surface plane and through
the depth.
Residual stress measurement was carried out in
order to determine its magnitude and stress
distribution generated during the welding repairs.
These measurements were made in the
experimental laboratory of Engineering Center
Industrial Development (CIDESI, Queretaro
Mxico) through an equipment of X-ray
diffraction Phillips brand X-PERT model, which
radiation source has Chromium (Cr K). The
data were analyzed by the X'PERT PRO
software.
The residual stresses measurement was made
inside of the weld joint in five points located at: a)
welding center, b) 5 mm away from the center of
the weld bead to both ends c) 35 mm away from
the center of welding toward both ends, as
illustrated in Fig. 2a. The diffraction peak used to
measure residual stresses was a ferrite peak
(211) located at an angle of 156.81 in axis 2.
For each point measurements were taken at an
angle of: a) = 0 (measured in the
circumferential direction and b) = 90
(measured in the axial direction). In the
calculation of the residual stresses are using an
624
Ni Mo Al V T N
0.05 0.05 0.025 0.036 0.016 0.0045
elastic modulus of 201 GPa and a Poisson's ratio
of 0.3 (values tabulated in software for steel).
2.4 Stress Corrosion Cracking
Assessment
The susceptibility to stress corrosion cracking
(SCC) of welded joints of API X52 pipeline steel
with up to four repairs was evaluated using
SSRT according to NACE TM-0198 standard
[25]. The SSRT were performed in air as
reference, and in soil solution called NS4 at low
and high pH, both at room temperature and at
strain rate of 1x10-6 s-1. The NS4 solution contain
NaHCO3:0.483g/L, CaCl2:0.181 g/L,
MgSO4:0.131 g/L and KCl:0.122 g/L. The NS4
pH solution was around 8.5 and after was
adjusted with HCl and NaOH.
The SSR specimens were machined according
the dimensions established in NACE TM 198
[25]. Cylindrical tensile specimens were
transversal machined to the girth weld as is
shown in Fig. 2b.
3. RESULTS AND DISCUSSION
3.1 Microstructure
Microstructural characterization through optical
microscopy of the welding joint is shown in
Fig. 3. This characterization was made in the
three different regions of the weldments. The
microstructure of the weld is ferriticbainitic
acicular. The heat affected zone (HAZ) and base
metal microstructure shows a structure of grains
of ferrite with perlite in the grain boundary. The
 Contreras et al.; BJAST, 6(6): 621-634, 2015; Article no.BJAST.2015.117
characterization of the microstructure in the HAZ
for each weld repair condition does not reveal
significant changes in the type of microstructural
constituents, in comparison with the
microstructure found in the as-welded condition.
Optical micrographs of the coarse grained heat
affected zone (CGHAZ) revealed that increasing
the number of weld repairs promotes grain
growth in the CGHAZ [5].
Mechanical properties obtained for the different
weld repair condition were shown elsewhere [26].
The yield strength and the ultimate tensile
strength was 380 and 484 MPa, respectively.
The values of yield strength (YS) and ultimate
tensile strength (UTS) satisfy the specified
minimum values of the material according to the
API 5L standard [27], whose values are 359 and
455 MPa for YS and UTS respectively.
After carried out the welding repairs, each
welding was subjected to internal surface
residual stress measurements using the X-ray
diffraction technique. Five residual stress
measurements were made on the inner surface
of the pipe for both circumferential and
longitudinal direction in reference to the pipe and
not the weld as is shown in Fig. 2a.
3.2 Hoop Residual Stresses
To assess the effects of the number of welding
repairs, residual stress distributions in the hoop
a)
Fig. 2. a) Location of the residual stress measurements, b) cross section of the welding and
SSRT specimen
Fig. 3. Typical weld joint microstructures for X52 steel, a) weld bead, b) heat affected zone and
c) base metal
625
direction through five measurements were
performed. Fig. 4 show the distribution of hoop
residual stresses for each welding repair. In
general, the hoop residual stress values are
compressive on the inside surface of the welding
joint. The compressive residual stresses in the
hoop orientation are less damaging than tensile
on the inner surface when considering the
structural integrity of girth welds.
The surface measurements of residual stresses
are in the range of 225358 MPa. It is observed
that residual stresses are greater in the first
repair reaching values from 290 to 358 MPa,
which can be attributed to grain growth due to
heat input from the welding process. In the
subsequent repairs the welding process
generates a grain refinement, which reduces
residual stresses. Residual stresses can also be
affected by thermal cycles and its analysis
provides a potential for estimating the hardening
of the weld zone, however the other parameter
such as carbon equivalent in composition of steel
alloy must be also considered. Preheat effect on
thermal cycle and residual stress was studied by
Aalami et al. [28].
The higher stresses (first repair) in the hoop
direction reach values of about 77% of the
ultimate tensile strength (460 MPa), approaching
to the yield strength of the steel (360 MPa).
SSRT specimen
b)
welding
 Contreras et al.; BJAST, 6(6): 621-634, 2015; Article no.BJAST.2015.117

-200 noticeable in the first and second repair.

-220
0R 1R 2R 3R 4R Additionally, in the longitudinal direction always
will be more variability by the anisotropy of the
-240
material.
Residual stress (MPa)

-260
-200
-280
0R 1R 2R 3R 4R
-210
-300

-320 -220

Residual Stress (MPa)

-340 -230

-360 -240

-380
-250
-40 -30 -20 -10 0 10 20 30 40
Distance from the weld center line (mm) -260

-270
Fig. 4. Hoop residual stresses distribution
-280
The hoop stresses are generally more severe -40 -30 -20 -10 0 10 20 30 40

than the longitudinal stresses particularly on the Distance from the weld centerline (mm)
inner surface of the pipe. The most severe
residual stresses are generated for the first and Fig. 5. Longitudinal residual stresses
four welding, and its magnitude increase as distribution
move away from weld center line. These
changes can be attribute to the difference in the Different behavior in the longitudinal residual
number of welding bead required for each repair stress distribution on the inner surface was
and additionally to the size of the welding beads reported by Rybicki [32], who evaluated the
produced [29-31]. effect of pipe thickness on residual stresses in
circumferential welds of 304 stainless steel, in
3.3 Longitudinal Residual Stresses nominal diameter of 4 and thickness of 0.120",
0.237", 0.337" and 0.531"; and in nominal
To evaluate the effects of welding repair number diameter of 10" in thicknesses of 0.165", 0.365",
on the inner surface of the pipeline, residual 0.593" and 1.125". In the case of pipe of 10" in
stress distributions in the longitudinal direction diameter and thickness of 1.125" it was observed
through five measurements were carried out. compressive longitudinal residual stress
Fig. 5 show the distribution of longitudinal distribution in the centerline of the welding,
residual stresses for each welding repair. As well increasing the stress magnitude as the distance
as hoop residual stress values are compressive increases from the weld.
inside surface of the pipe, the stresses in the
longitudinal direction are compressive too. A Rybicki [32] explain this difference in the stress
lower magnitude of residual stresses was found distribution in terms of rigidity of the system. A
along the weld joint in the longitudinal direction circumferential welding with thin thickness
than in hoop direction. The stresses measured in exhibits greater local deformation to the center,
the longitudinal direction reach values of about close to the weld, than thicker pipelines. This
58% of the ultimate tensile strength (460 MPa) in local deformation is caused by the combination
comparison with 77% in hoop direction. of shrinkage during cooling of the weld and
decrease in stiffness of the system (lower
The longitudinal residual stresses in the inner thickness). This strain causes local flexion
pipe surface did not follow a consistent pattern towards the center and this generates tension
as in the hoop direction. But it is clear that its residual stresses toward the inside of the pipe
magnitude increases as move away from weld and compressive residual stresses to the outer
center line, obtaining the major residual stresses side. On thicker pipes this phenomenon is
at 35 mm from the centerline. This fluctuation in minimized or not generated, being the case for
the longitudinal residual stresses could be the pipe of 10" in diameter and 1.125" of
attributed to several factors like different thickness, that resists welding shrinkage during
microstructure, which is produced by the the cooling, creating compressive stresses on
application of several girth welds, which is more the internal face of the pipe.

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3.4 Assessment of SCC Susceptibility
One of the principal effects of residual stresses is
to accelerate (tensile stresses), or in some cases
retard (compressive stresses), the nucleation
and growth of cracking in pipelines and
structures subject to cyclic loading and exposed
to corrosive environments. Residual stresses can
alter the shape of surface cracks in thick welds,
causing them to grow in the time and when they
reach a threshold size suddenly produce a
failure. They can cause crack growth to occur in
regions subject to purely compressive cycling
where fatigue would normally not be a problem
[33]. They have also been shown to accelerate
environmentally assisted cracking in structures
subject to static loading.
SCC susceptibility in welded joints of API X52
steel pipe with up to four welding repairs was
evaluated using slow strain rate tests (SSRT)
according to NACE TM-0198 standard [25]. The
tensile specimens were exposed to the soil
solution at low and high pH. Results obtained
from these tests are shown in Fig. 6.
Table 2 show a summary of the mechanical
properties obtained from the curves of Fig. 6.
Considering the yielding strength (YS), ultimate
tensile strength (UTS), reduction in area (RA),
elongation plastic (EP) and strain (e), there is a
tendency to increases in the first and second
repair, but in third repair decrease with a slight
increase in the fourth repair.
The SCC susceptibility was evaluated obtaining
SCC index of the mechanical properties from
SSRT. SCC index from yielding strength ratio
(YSR), ultimate tensile strength ratio (UTSR), the
reduction in area ratio (RAR), elongation plastic
ratio (EPR) and strain ratio (eR) were obtained
as is shown in Fig. 7. These ratios are obtained
from comparing the mechanical properties
obtained in the NS4 solution with the mechanical
properties obtained in the controlled environment
(air). When the X52 steel is exposed to NS4
solution YS, UTS and ductility of the welded
joints shown a decrease [5]. SEM observations
of SSRT specimen revealed absence of lateral
corrosion and neither secondary cracking was
observed. The metallographic observations of
the fractured specimens show that most SSRT
specimens failed in the base metal/heat affected
zone interface.
3.5 Relation Between Residual Stresses
and Stress Corrosion Cracking Index
(SCC)
SCC index obtained from the mechanical
properties of SSRT at low and high pH showed in
Table 2 are plotted in Fig. 7 and they are related
to residual stresses. Ratios in the range of 0.8-
1.0 normally denote high resistance to SCC,
whereas low values (i.e. <0.5) show high
susceptibility [25]. The specimens tested in air
showed the maximum %RA. SSR specimens
tested in air exhibit a strain about 16-19%
meanwhile the specimens tested in NS4 solution
showed a strain between 14-18%. It is clear that
corrosive solution has an effect on the
mechanical properties.

Table 2. Mechanical properties obtained from the SSR tests to assess the SCC

Condition Environment YS (MPa) UTS (MPa) RA (%) EP (%) e (%)

BM Air 386.1 475.2 89.10 23.26 25.72
0 Rep 356.0 437.5 85.74 15.00 17.39
1 Rep 379.9 464.2 88.10 16.18 18.14
2 Rep 384.1 456.2 88.53 16.69 18.69
3 Rep 359.7 427.4 84.60 14.37 15.94
4 Rep 379.2 455.9 86.34 15.51 17.84
BM NS4, pH 3 396.8 464.8 88.13 19.72 20.03
0 Rep 325.9 423.0 84.10 14.17 16.39
1 Rep 322.5 427.5 86.84 15.47 16.86
2 Rep 351.8 438.2 86.90 16.69 17.75
3 Rep 318.1 354.9 83.91 13.78 14.55
4 Rep 329.7 428.8 85.01 15.00 15.98
BM NS4, pH 10 357.0 467.7 87.62 18.34 22.67
0 Rep 316.0 428.4 83.16 14.98 17.05
1 Rep 324.9 446.3 86.86 15.51 15.74
2 Rep 340.6 415.2 86.88 16.22 18.50
3 Rep 344.6 436.8 82.30 12.99 16.45
4Rep 318.0 412.1 86.10 14.60 14.99

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500 500
a) NS4, pH=3 b)
450 Air 450

400 400

350 350

Stress (MPa)
Stress (MPa)

300 300

250 250

200 0R 200
2R
150 4R 150 1R
2R
BM 0R
BM
100 1R 100
4R

50 50 3R
3R
0 0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 0 2 4 6 8 10 12 14 16 18 20 22 24 26

Strain (%) Strain (%)

500
NS4, pH=10
450 c)
400

350
Stress (MPa)

300

250

200

150
2R
1R
0R
100
4R 3R
BM
50

0
0 2 4 6 8 10 12 14 16 18 20 22 24 26
Strain (%)

Fig. 6. Stress-strain profiles obtained from the SSRT in function of pH and number of repairs

The strength, elongation and reduction in area circumferential welds [34-43]. They all reported
decreases slightly when the samples are that both residual stresses resulting from repair
exposed to the NS4 solution [5]. According to are tensile on the inner side of the pipe on the
SCC index, it is clear that the specimens tested center line of welding, decreases as moving
in the NS4 solution does not exhibited away from this and become compressive toward
susceptibility to SCC. Additionally, secondary areas away from the weld. This difference in the
cracks or corrosion in the gauge section of SSRT distribution of residual stress on the inner surface
specimens were not observed. can be explained according to the work of
Rybicki [32] in terms of the stiffness of the
The material susceptibility to SCC depends of system and based on the work of Dong
many factors such as elemental composition, [34,39,40,42,43], Bouchard [36,37] and Elcoate
metallurgical factors, corrosive environment, pH [38] relating to the length of repair. Compared to
and residual stresses mainly. According to the McGaughy work [29,30], the thickness used in
results of residual stress assessment it is clear this work is about twice (6.52 mm versus 11.1
that the level of stresses did not show a mm) so that the thicker tubing can withstand
significant effect on the SCC susceptibility. shrinkage during cooling welding. Respect to the
length of repair, the length reported by
As mentioned above, and according to Fig. 4 and McGaughy was 203 mm (120 arc lengths) and
5 for the different welding repair conditions, in this study the repair was the entire
stress values in the longitudinal and circumference (360), so it is expected to
circumferential direction are compressive on the generate lower levels of residual stresses. This
inner surface of the pipeline. These residual combined effect of increased stiffness and repair
stress results at the inner face of the pipe do not longer favor the generation of compressive
match those reported by McGaughy [29,30] or residual stresses on the inner face of the pipe as
with some other repairs concerning indicated by the results reported in Figs. 4 and 5.

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 Contreras et al.; BJAST, 6(6): 621-634, 2015; Article no.BJAST.2015.117

1.00
YSR
0.96 UTSR
SCC index RAR
0.92 EPR
eR
0.88
0.84 pH-10

1.00
YSR
0.96 UTSR
SCC index

RAR
0.92 EPR
eR
0.88
0.84 pH-3
Residual stresses

-240
-260
-280
-300
-320 Longitudinal Circumferential Average

0R 1R 2R 3R 4R
Repairs
Fig. 7. SCC index obtained from the mechanical properties of SSRT related to residual
stresses

The longitudinal residual stress reach values of
58% and 77% for the hoop residual stress relate
to the steel strength, but all them are
compressive and they are not enough to produce
SCC. The stresses exerted on the pipelines
steels are complex in nature, and should be a
combination of stresses related to the internal
operating pressure, residual stress from the pipe
fabrication, residual stress from the welding and
all the possible external stresses.
An attempt to relate the residual stresses with
the SCC index is shown in Fig. 8. The average of
residual stresses (longitudinal and
circumferential) in function of welding repairs was
plotted in order to compare with the average of
SCC index obtained from the different
mechanical properties (YSR, UTSR, RAR, EPR
and eR). It is observed that welding repair with
higher residual stresses presented the lower
SCC index. That is to say, increasing the residual
stresses the SCC susceptibility increases.
However, it should be noted that compressive
residual stresses measured did not generate
SCC in the API X52 steel under the conditions
studied. In all the cases the SCC index was
above 0.8 and not secondary cracks were
observed in the gauge section of the specimens.
In the SCC study it is clear that we only evaluate
the residual stress due to the welding repairs,
and the stresses evaluated were superficial and
compressive inside surface of the pipeline. The
maximum values for the residual stresses
evaluated belong to 35 mm to the right and
35mm to the left of the weld center line, which
reach values between 220 and 270 MPa for the
longitudinal residual stresses. Meanwhile for the
circumferential direction reach values between
230 and 358MPa. It is obvious that in order to be
the X52 steel susceptible to SCC must be reach
higher residual stresses. In addition, these
stresses must be tensile and not compressive.

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1.00
0.98 pH 3
0.96 pH 10
SCC index

0.94
0.92
0.90
0.88
0.86

-230 0R 1R 2R 3R 4R
Average residual stresses

-240
-250
-260
-270
-280
-290
-300
0R 1R 2R 3R 4R
Repairs
Fig. 8. Average of residual stresses related to average of SCC index

From this asseveration, it is evident that the
region with high residual stresses prior to
generate cracks in the steel due to the
combination of soil solution and the strain
exerted, should favor pitting formation and not
cracking. Initiation of micro-cracks from these
pits may depend on geometrical form of the pit
and stresses state can be established at given
pitting. This favorable condition can appear with
increasing the soil exposition time and reducing
the rate of constant load applied on the SSRT.
Thus, the pits generate in the high stress regime
should be favorable to develop high internal
stresses and initiation of cracks from a pit.
The complexity of cracking phenomena results
from the dependence of metallurgical,
mechanical and environmental parameters that
may influence both crack initiation and
propagation [44-47]. Previous studies for high
pH-SCC demonstrate that mechanism involves
anodic dissolution for crack initiation and
propagation [48,49]. By the contrary, it has been
observed that low pH-SCC is associated with the
dissolution of the crack tip and sides, and
generally is corrosion products are observed in
the crack. This type of SCC is accompanied by
the ingress of hydrogen into the steel [5,45-50].
3.6 Fracture Behavior
After carried out the SSR tests, the fracture
surfaces were observed by SEM in order to
characterize the type of fracture and to assess
the stress effects together with the environment
in the susceptibility to cracking. The fracture
surfaces of specimens tested in NS4 solution
with low and high pH exhibited a ductile type of
fracture, which was characterized by microvoids
coalescence. The neck formation before the
samples failed was observed [5]. This was
reflected in the assessment of reduction area on
the fracture surface. Most studies of SCC in near
neutral environments resulted in transgranular
fracture type [19,48-51].
Fractured samples from SSR tests were
longitudinal cut and polished in order to observe
if there are cracks in the gauge section originated
by the simultaneous action of corrosive solution
and stresses exerted. Optical micrographs from
longitudinal sections of SSRT specimens tested

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in NS4 solution with low and high pH are shown stresses in the inside surface of the weldment
in Figs. 9 and 10. The specimens tested in NS4 are compressive and as such, are no damaging
solution with low and high pH for the different as the tensile residual stresses.
conditions of repair, the failure generally
occurred in the base metal and BM/HAZ
interface without presence of secondary cracks a)
3 mm
in the gauge section. These observations are
agreed with the SCC index obtained from
mechanical properties evaluated from SSRT
(YSR, UTSR, RAR, EPR and eR). b) b)
3 mm
Most results about cracking in near neutral
environments have origin from pits [52,53]. The
location of the cracks in the micro-pits can be d)
related to the stress intensification in this site. 3 mm
Continuous loading produce a micro strain in the
bottom of the pit facilitating the pit-to-crack
transition in regions with the highest stress c)
concentration. Pitting in neutral pH environment 3 mm
preferentially occurs at surfaces with high
residual stresses as a result of galvanic reactions
[52]. e)
3 mm
In welded joints of low carbon steels the HAZ
was characterized by a combination of fine and Fig. 9. Optical micrographs of gauge section
coarse grained polygonal ferrite structure and of fractured samples from SSRT performed in
fine perlite particles [54,55]. In the weld metal, NS4 solution with pH 3 showing failure zone,
the constituents of complex ferrite were low a) as welded; b) first repair; c) second repair;
temperature transformation products formed d) third repair; e) fourth repair
during continuous cooling such as acicular ferrite
and bainite microstructure [14,26].
a)
3 mm
Optical micrographs of the coarse grained heat
affected zone (CGHAZ) revealed that increasing
the number of weld repairs promotes grain
growth in the CGHAZ [5,54,55], being this zone
the most susceptible to failure. 3 mm

Taking account the results published and

considering the standards and recommended
practices on pipeline fabrication and installation,
c)
3 mm
not more than two welding repairs may be
carried out in the same area. The rule was
established perhaps because of a lack of d)
knowledge on the effects of repeated weld 3 mm
repairs on the properties of the weld.

Considering the residual stresses, the corrosive

solution (NS4) and X52 steel, the evaluation
through the mechanical properties to obtain SCC
index and SEM observation in the gauge section
of the specimens to find cracks, revealed that
X52 steel weldments with up to four repairs are
not susceptible to SCC despite of high
compressive residual stresses level. The
3 mm e)
Fig. 10. Optical micrographs of gauge section
of fractured samples from SSRT performed in
NS4 solution with pH 10 showing failure zone,
a) as welded; b) first repair; c) second repair;
d) third repair; e) fourth repair

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4. CONCLUSIONS
The influence of residual stresses on SCC
susceptibility due to multiple welding repairs in
X52 pipeline steel was studied. Relation between
microstructure, mechanical properties and
residual stresses on the welding joint was
evaluated. The welding joint evaluated presented
different levels of residual stresses, offering good
SCC resistance in a synthetic soil solution at low
and high pH. Presence of cracks was not
observed along the gauge section specimens.
These findings are agree with the results
obtained from ratios of mechanical properties
(YSR, UTSR, RAR, EPR, eR) which resulted in
high ratios (0.8-1), indicating that X52 steel with
up to four repairs and the residual stress
generated not contribute to produce SCC. After
carried out the SSRT, the metallographic
observations of specimens showed that failure
occurs in the base metal and BM/HAZ interface.
It is observed that region with high residual
stresses before generating cracks in the steel
surface due to the combination of soil solution
and stress applied, should favor pitting formation
and not cracking. It is suggested that initiation of
micro-cracks from these pits may depend on the
dissolution rate and morphology of the pitting and
stresses on the bottom of the pitting. This
favorable condition could appear increasing the
soil exposition time of the steel and reducing the
strain rate applied on the SSRT.
COMPETING INTERESTS
Authors have declared that no competing
interests exist.
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